Nested pair of blanks

ABSTRACT

The invention relates to a nested pair of blanks on a unitary sheet which minimizes the amount of scrap sheet material (i.e., sheet scrap) upon separation of the blanks and construction of containers formed from the blanks. The nested pair of blanks provides a first blank for forming a container, a second blank for forming an identical container, and a non-linear separation interface that connects the first and second blanks to one another in a rotationally inverted relationship. The nested configuration reduces the amount of sheet scrap in the sheet. The invention further relates to a container formed from the first or second blank having features that reduce sheet scrap and offset the potential weakening of the container bottom resulting from reduced overlapping sheet material.

BACKGROUND OF THE INVENTION

This invention relates to a nested blank arrangement on a unitary sheetwith features which minimize scrap sheet material (i.e., sheet scrap)while strengthening the bottom of a container formed from one of theblanks. More specifically, the invention is a nested pair of blanks on aunitary sheet which minimizes the amount of sheet scrap upon separationof the blanks and construction of containers formed from the blanks. Thenested pair of blanks further minimizes the amount of sheet materialrequired to form container bottoms. Stated differently, the increasednesting between the panels and flaps of the blanks on the sheet reducesthe amount of overlapping sheet material on the bottom flaps forming thecontainer bottom. The invention further relates to a container formedfrom one of the blanks and having an automatic bottom, wherein notchededges of the bottom panels correspondingly engage one another to form acontainer bottom and offset the potential weakening of the containerbottom resulting from reduced overlapping sheet material.

The positioning of blanks on a sheet such that portions of the blanksare connected to one another is referred to as nesting or a nestedarrangement. Known nested arrangements of blanks are formed by adie-cutting machine that cuts and scores a web of board (e.g.,paperboard) into one or more sheets defining one or more blanks. Inpractice, the die-cutting machine cuts and scores a single sheet ofboard into one or more adjacent blanks. The unused board material of thesheet located between the adjacent blanks is scrap material which may bediscarded or recycled. In an effort to reduce the cost of producingcontainers from the blanks, manufacturers attempt to minimize the amountof board in the blanks.

As known in the industry, the cost of the board material contributessignificantly to the total cost of producing containers. Furthermore,when die-cutting the sheet of board into multiple adjacent blanks, it isdesirable to form the blanks as close to one another as possible. Thepositioning of the blanks close to one another reduces the amount ofsheet scrap and increases the number of blanks simultaneously formedfrom the board by the die-cutting machine. Specifically, the die-cuttingmachine may accommodate more blanks at the same time if the blanksoccupy a smaller area.

Known nested arrangements of blanks often fail to sufficiently reducethe amount of sheet scrap, thereby increasing the cost of manufacturingblanks. Some nesting arrangements incorporate linear interfaces thatconnect, for example, a first and second blank. These types ofarrangements fail to achieve the reduction in sheet scrap attained bythe present invention as described herein.

Further, known nested arrangements attempting to minimize sheet scrapresult in containers having weakened bottoms due to the decrease in theamount of overlap of the bottom panels secured to each other. Thepresent invention provides a pair of nested blanks on a unitary sheethaving a nested arrangement, a non-linear separation interface, andengagement notches which address these problems.

SUMMARY OF THE INVENTION

The invention is a nested pair of blanks on a unitary sheet having afirst blank for forming a container, a second blank for forming anidentical container, and a non-linear separation interface that connectsthe first and second blanks to one another in a rotationally invertedrelationship (i.e., half-turn rotationally inverted with respect to oneanother). Advantageously, the non-linear separation interface reducesthe amount of sheet scrap in the sheet.

Although efficient for manufacturing purposes, the non-linear separationinterface also reduces the amount of sheet material available to form acontainer bottom in a container formed from one of the blanks. Thereduction in area of the bottom panels forming the container bottompotentially weakens the container bottom. The invention addresses thepotentially weakened container bottom by providing bottom panels havingnotched edges that correspondingly engage one another upon constructionto counter the reduced bottom panel area (i.e., overlapping material)and strengthen the container bottom.

In one embodiment, the invention is a nested pair of blanks on a unitarysheet having a first blank for forming a container, a second blank forforming an identical container, and a non-linear separation interfacethat connects the blanks to one another in a rotationally invertedrelationship that reduces sheet scrap. As set forth above, the inventionincorporates blanks having notched edges that correspondingly engage oneanother upon construction to form a container bottom upon separation ofthe blank and construction of the container. The engagement notchesstrengthen the container bottom and counter the effect of reducedoverlapping material in the container bottom (i.e., potentially weakenedbottom).

More specifically, the invention provides first and second blanks havingone or more body panels that are connected to one another along verticalfold lines. In further detail, each of the body panels of the first andsecond blanks include a front panel having opposing first and secondside panels, and a rear panel that is connected to the front panel bythe second side panel.

The first and second blanks also include bottom panels connected toedges of the body panels. The bottom panels of each of the first andsecond blanks include a first bottom closure panel connected to an edgeof the front panel, and a second bottom closure panel connected to anedge of the rear panel. At least one of the bottom panels of the firstblank is connected to and nested vertically with at least one of thebottom panels of the second blank.

The first and second blanks may also include bottom flaps connected toedges of the respective body panels. In one embodiment, each of thefirst and second blanks include a first bottom closure flap connected torespective edges of the first side panels, and a second bottom closureflap connected to respective edges of the second side panels.

The adjacent bottom panels and flaps of the blanks define the non-linearseparation interface. Thus, one or more of the adjacent bottom closurepanels and one or more of the adjacent bottom closure flaps of the firstand second blanks may define the non-linear separation interface.

Each of the nested blanks includes notched edges that correspondinglyengage one another to form container bottoms upon separation of theblanks from the sheet and construction of the containers. The notchededges define engagement notches that permit the reduction in sheetscrap, while maintaining sufficient strength in the container bottom.

First and second locking closure flaps connected to respective edges ofthe first and second side panels of the first and second blanks securethe tops of the containers formed from the blanks. In the unitary sheet,the first and second locking closure flaps of the blanks are positionedopposite the non-linear separation interface. This particular embodimentalso provides first and second top closure panels connected torespective edges of the front and rear panels of the blanks. The firstand second top closure panels are positioned on the sheet opposite thenon-linear separation interface and further secure the tops of thecontainers formed from the blanks.

The invention further provides first and second tuck flaps connected torespective edges of the first and second top closure panels of theblanks. The tuck flaps secure the first and second top closure panels toone another. The tuck flaps are positioned on the sheet opposite thefront and rear panels of the blanks. Glue flaps are connected torespective edges of the rear panels of the blanks and form a part of themanufacturer's joint upon construction of the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages of the invention and themanner in which the same are accomplished will become clearer based onthe following detailed description taken in conjunction with theaccompanying drawings in which:

FIG. 1 is a partial top plan view of known nesting arrangements ofblanks on a unitary sheet illustrating sheet scrap in parallelcross-hatched lines between the blanks;

FIG. 2 is a perspective view of a known container having an automaticbottom illustrating overlapping sheet material in a container bottom inhidden double cross-hatched lines;

FIG. 3A is a partial perspective view of one bottom panel of a knowncontainer illustrating the area of overlap between the bottom panels indouble cross-hatched lines;

FIG. 3B is a partial perspective view of another bottom panel of a knowncontainer illustrating the area of overlap between the bottom panels indouble cross-hatched lines;

FIG. 4 is a top plan view of one embodiment of a nested pair of blankson a unitary sheet of the invention illustrating sheet scrap in parallelcross-hatched lines;

FIG. 5 is an enlarged top plan view of a portion of one embodiment of anested pair of blanks of the invention depicting notched edges in bottompanels of the blanks;

FIG. 6 is a partial perspective view of a container having an automaticbottom formed from one embodiment of a nested pair of blanks of theinvention illustrating overlapping sheet material in a container bottomin hidden double cross-hatched lines;

FIG. 7 is an enlarged perspective view of a portion of a containerformed from one embodiment of the nested pair of blanks of the inventionillustrating overlapping sheet material in a container bottom in hiddendouble cross-hatched lines;

FIG. 8A is a partial perspective view of one bottom panel of a containerformed from one embodiment of the nested pair of blanks of the inventionillustrating the area of overlap between the bottom panels in doublecross-hatched lines;

FIG. 8B is a partial perspective view of another bottom panel of acontainer formed from one embodiment of the nested pair of blanks of theinvention illustrating the area of overlap between the bottom panels indouble cross-hatched lines;

FIG. 9A is a partial perspective view of the bottom of a containerformed from one embodiment of the nested pair of blanks of the inventionillustrating the initial stages of the formation of a container bottom;

FIG. 9B is a partial perspective view of the bottom of a containerformed from one embodiment of the nested pair of blanks of the inventionillustrating latter stages of the formation of a container bottom; and

FIG. 9C is a partial perspective view of the bottom of a containerformed from one embodiment of the nested pair of blanks of the inventionillustrating the completed formation of a container bottom.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described more fully hereinafter withreference to the accompanying drawings, in which multiple embodiments ofthe invention are shown. This invention may, however, be embodied indifferent forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete and will fully conveythe scope of the invention to those skilled in the art. Like numbersrefer to like elements throughout. Further, like numbers with the primenotation refer to like or similar elements of the structure.

Packaging is typically formed from packaging blanks, or blanks forshort. It will be understood that as used herein the term “blank” mayinclude cardboard, rigid paper, flexible plastic, or similar productsmade of paperboard or plastic. In particular, the packaging industryfavors the use of one-piece flexible blanks, which are readilyincorporated into automated processes for forming containers. The term“unitary sheet” refers to material having a broad, continuous surface soconnected that it is possible to pass from any one point of the surfaceto any other point without leaving the surface. Sheet may also refer toseparate pieces of, for example, paperboard used to form blanks.

It will be understood by those skilled in the art that the term“container” as used herein refers to various embodiments of the presentstructure for retaining a variety articles as formed from the variousembodiments of the blank described below.

The term “panel” used in conjunction with the nested pair of blanks ofthe present invention refers to the major component part of a blank orcontainer, and defines the major partition elements of the blank orcontainer. Those skilled in the art will also appreciate that panelsinclude edges defined as the line of intersection of two surfaces or aborder. A “free edge” of a panel refers to an edge that does notintersect with another surface or panel.

The term “flap” refers to a secondary blank or container element that istypically hinge-connected along a free edge of a panel or another flap.It will be understood that the term “tab” refers to a tertiary elementof the blank or container that is generally hinged to a portion of afree edge of a panel or flap, or struck from within the plane of a panelor flap.

It will be understood by those skilled in the art that the terms “toppanel” and “lower panel” may also refer to “lower panel” and “upperpanel” dependent upon the perspective of the individual viewing theapparatus. It will also be appreciated that the term “top” implies theopposite of “bottom.”

With reference to the orientation of the sheet in FIG. 4, it will beunderstood that the terms “internal surface” and “external surface” maybe referred to as “inside surface” and “outside surface.” Stateddifferently, the term internal surface implies the surface of thecontainer closest to the interior of the container. Thus, it will beunderstood that the term external surface implies the side of thecontainer opposite the internal surface (i.e., the side farthest fromthe interior of the container).

The dimensions or measurements for containers will typically beexpressed in the order of length (L), width (W), and depth (D), whereinL is typically the larger dimension at the open end of the container, Wis usually the smaller dimension at the open end of the container, and Dis the distance between the open ends of the container (e.g., L×W×D).With reference to the orientation of the sheet in FIG. 4, it will beunderstood that the term “width” refers to a distance measured from theleftmost portion of the sheet to the rightmost portion of the sheet.

Further, as used herein the concept of a panel being “between” two otherpanels does not necessarily imply that the three panels or flaps arecontiguous (i.e., in intimate contact). Rather, as used herein, theconcept of one panel being between two other panels is meant to describethe relative positions of the panels within the blank or containerstructure, respectively.

Similarly, the concept of a first panel being connected to a secondpanel by a third panel, “opposite” the second panel, merely describesthe relative positions of the first and second panels within the blankstructure. It will further be understood that the term “finished” meanscoated with a material to produce an attractive glossy finish. The term“finished” will also be understood to mean the inclusion of printedmaterial or other identifying indicia (e.g., a company's logo).

It will be understood by those skilled in the art that the term “score”refers to a crease along which the adjacent components or portions of acomponent of the blank are folded without cracking or breaking to form acontainer. It will be understood that the term “cut-score” refers to animpression formed by a cutting tool (e.g., a punch, die, or blade) thatextends partially through a sheet of paperboard or the like. The term“perforations” refers to a series of holes or impressions formed by acutting tool (e.g., a punch or die) that permits easy separation of, forexample, panels.

It will be further understood that the term “fold line” or “score line”refers to a crease along which the adjacent components of a blank arefolded without cracking or breaking to form a container. The term“secured” may refer to adhered with adhesive (e.g., glue) or bonded withheat.

The term “substantially rectangular” is meant to succinctly describe asimple geometric shape approximating a rectangle. Similarly, the term“substantially parallel” is meant to describe the spatial relationshipbetween, for example, one panel to another panel, wherein therelationship is approximately parallel.

Those skilled in the art will also appreciate that the term “adjacent”refers to two or more, for example, panels that have a common border orare in close proximity to one another. Nevertheless, it will beunderstood that adjacent may or may not imply contact, but alwaysimplies the absence of anything of the same kind in between.Furthermore, as used herein, it will be understood that the term“article” will refer primarily to consumer products that are packagedfor shipment (e.g., pharmaceuticals, consumables, etc.). It will beunderstood, however, that “article” may also refer to any number ofgoods such as individually packaged consumables for humans and animals,as well as individually packaged non-consumables.

As used herein, the term “separation interface” refers to an area of thesheet defining a common border between the pair of nested blanks. Stateddifferently, the term “separation interface” refers an area of the sheetconnecting the pair of nested blanks that is capable of coming apart anddividing the sheet into separate components (i.e., blanks).

An overall view of an embodiment of a nested pair of blanks on a unitarysheet of the invention is set forth at 10 in the top plan view of FIG.4. In general terms, the invention provides a first blank 11 for forminga container 60, a second blank 12 for forming an identical container,and a non-linear separation interface 13 that connects the first andsecond blanks 11, 12 to one another in a rotationally invertedrelationship (i.e., half-turned and inverted with respect to oneanother). As a novel feature of the invention, the non-linear separationinterface 13 reduces the amount of sheet scrap S in the sheet 10 andimproves manufacturing efficiencies. In one embodiment, the sheet 10 isformed from paperboard.

Referring to FIG. 4, the first and second blanks 11, 12 include one ormore body panels 14, 15, 16, 17, 20, 21, 22, 23 connected alongsubstantially vertical fold lines 18 and oriented horizontally. Infurther detail, the body panels 14, 15, 16, 17 of the first blank 11include a substantially rectangular front panel 14 having opposing firstand second side panels 15, 16, and a substantially rectangular rearpanel 17 connected to the front panel 14 by the second side panel 16. Inlike fashion, the body panels 20, 21, 22, 23 of the second blank 12include a substantially rectangular front panel 20 having opposing firstand second side panels 21, 22, and a substantially rectangular rearpanel 23 connected to the front panel 20 by the second side panel 22.The body panels of the first and second blanks 11, 12 form the majorcomponent parts of the respective blanks.

The first blank 11 may include one or more bottom panels 25, 26connected to edges of the body panels 14, 15, 16, 17. The second blank12 also includes one or more bottom panels 30, 31 connected to edges ofthe body panels 20, 21, 22, 23. Each of the first and second blanks 11,12 may also provide one or more bottom flaps 27, 28, 32, 33 connected toedges of the body panels 15, 16, 21, 22 of the respective blanks. Thebottom panels 25, 26, 30, 31 and bottom flaps 27, 28, 32, 33 of theblanks 11, 12 form a part of the respective container bottoms.

Still referring to FIG. 4, the bottom panels 25, 26 of the first blank11 include a first bottom closure panel 25 connected to an edge of thefront panel 14, and a second bottom closure panel 26 connected to anedge of the rear panel 17. Further, the bottom panels 30, 31 of thesecond blank 12 include a first bottom closure panel 30 connected to anedge of the front panel 20, and a second bottom closure panel 31connected to an edge of the rear panel 23. As discussed herein, thefirst and second bottom panels 25, 26, 30, 31 of the blanks engage oneanother respectively, during construction of the containers formed fromthe blanks.

With respect to the bottom flaps 27, 28, 32, 33, the first blank 11includes a first bottom closure flap 27 connected to an edge of thefirst side panel 15, and a second bottom closure flap 28 connected to anedge of the second side panel 16. The second blank 12 may likewiseinclude a first bottom closure flap 32 connected to an edge of the firstside panel 21, and a second bottom closure flap 33 connected to an edgeof the second side panel 22.

Each of the first and second bottom closure panels 25, 26, 30, 31 of thefirst and second blanks 11, 12 include first and second bottom glueflaps 35, 36, 37, 38 defined by a cut-score line 39 in the respectivebottom closure panels (see FIG. 4). During construction of a container60 from either of the blanks as illustrated in FIGS. 9B and 9C, aportion of the first bottom glue flap 35 is adhered to a portion of thefirst bottom closure panel 25. Further, a portion of the second bottomglue flap 36 is adhered to a portion of the second bottom closure panel26.

In combination with the corresponding engagement of the notched edges 24of the first and second bottom closure panels 25, 26 of the first blank,the glue flaps 35, 36 as adhered to portions of both closure panelsfacilitates the automatic formation of the container bottom 29 uponconstruction (see FIG. 9C). Specifically, upon the formation of themanufacturer's glue joint with a glue flap 56, the substantially flat,partially formed container 60 is expanded, thereby permitting theengagement notches 40 to secure the container bottom 29.

As configured on the unitary sheet 10 depicted in FIG. 4, at least oneof the bottom panels 25, 26 of the first blank 11 is connected to andnested vertically with at least one of the bottom panels 30, 31 of thesecond blank 12. In one embodiment, the first bottom closure panel 25 ofthe first blank 11 is connected to the second bottom closure panel 31 ofthe second blank 12, and the second bottom closure panel 26 of the firstblank 11 is connected to the first bottom closure panel 30 of the secondblank 12.

Still referring to FIG. 4, the adjacent bottom panels 25, 26, 30, 31 ofthe first and second blanks 11, 12 define the non-linear separationinterface 13. The non-linear separation interface 13 is further definedby one or more of the bottom closure flaps 27, 28, 32, 33 connected toedges of the body panels 15, 16, 21, 22 of the first and second blanks11, 12. Accordingly, one or more of the adjacent bottom closure panels25, 26, 30, 31 and one or more of the adjacent bottom closure flaps 27,28, 32, 33 of the first and second blanks 11, 12 may define thenon-linear separation interface 13 on the unitary sheet 10.

In one embodiment of the invention, the non-linear separation interface13 is defined by the first and second bottom closure panels 25, 26 ofthe first blank 11, and the first and second bottom closure panels 30,31 of the second blank 12. In this embodiment, the first bottom closurepanel 25 of the first blank 11 is connected to and nested verticallywith the second bottom closure panel 31 of the second blank 12.Furthermore, the second bottom closure panel 26 of the first blank 11 isconnected to and nested vertically with the first bottom closure panel30 of the second blank 12.

With reference to FIG. 4, one or more of the bottom closure panels 25,26 of the first blank 11 are connected to and nested vertically with oneor more of the bottom closure flaps 32, 33 of the second blank. Further,one or more of the bottom closure panels 30, 31 of the second blank 12may be connected to and nested vertically with one or more of the bottomclosure flaps 27, 28 of said first blank 11. In particular, the firstbottom closure panel 25 of the first blank 11 is connected to and nestedvertically with the second bottom closure flap 33 of the second blank12. Furthermore, the second bottom closure panel 26 of the first blank11 is connected to and nested vertically with the first bottom closureflap 32 of the second blank 12.

In further description, at least one of the bottom panels 25, 26 of thefirst blank 11 is connected to and vertically nested with at least oneof the bottom panels 30, 31 of the second blank 12 and at least one ofthe bottom flaps 32, 33 of the second blank 12. Specifically, the firstbottom closure panel 25 of the first blank 11 is connected to and nestedvertically with the second bottom closure panel 31 of the second blank12 and second bottom closure flap 33 of the second blank 12. Further,the second bottom closure panel 26 of the first blank 11 is connected tothe first bottom closure panel 30 of the second blank 12 and the firstbottom closure flap 32 of the second blank 12.

In continuing detail, at least one of the bottom panels 30, 31 of thesecond blank 12 is connected to and vertically nested with at least oneof the bottom panels 25, 26 of the first blank 11 and at least one ofthe bottom flaps 27, 28 of the first blank 11. In particular, the firstbottom closure panel 30 of the second blank 12 is connected to thesecond bottom closure panel 26 of the first blank 11 and the secondbottom closure flap 28 of the first blank 11. Further, the second bottomclosure panel 31 of the second blank 12 is connected to the first bottomclosure panel 25 of the first blank 11 and the first bottom closure flap27 of the first blank 11.

Still referring to FIG. 4, one embodiment provides at least one of thebottom flaps 27, 28 of the first blank 11 connected to and nestedvertically with at least one of the bottom panels 30, 31 of the secondblank 12. In more detail, the first bottom closure flap 27 of the firstblank 11 is connected to and vertically nested with the second bottomclosure panel 31 of the second blank. In another embodiment, the secondbottom closure flap 28 of the first blank 11 is connected to andvertically nested with the first bottom closure panel 30 of the secondblank 12.

Still further, at least one of the bottom flaps 32, 33 of the secondblank 12 may be connected to and nested vertically with at least one ofthe bottom panels 25, 26 of the first blank 11. Specifically, the secondbottom closure flap 33 of the second blank 12 is connected to andvertically nested with the first bottom closure panel 25 of the firstblank 11. Further, the first bottom closure flap 32 of the second blank12 is connected to and vertically nested with the second bottom closurepanel 26 of the first blank 11.

With reference to FIG. 5, each of the nested blanks 11, 12 includes oneor more notched edges 24 that correspondingly engage one another to formcontainer bottoms upon separation of the blanks from the sheet 11 andconstruction of the container 60. In particular, edges 24 of the bottompanels 25, 26 of the first blank 11 have engagement notches 40 thatcorrespondingly engage one another to form the container bottom uponseparation of the blank from the sheet and construction of thecontainer. In similar fashion, edges 24 of the bottom panels 30, 31 ofthe second blank 12 include engagement notches 40 that correspondinglyengage one another to form the container bottom upon separation of theblank from the sheet and construction of the identical container. Asillustrated in FIG. 5, one or more of the notched edges 24 define anglesA that are oriented on the sheet 10 at approximately 45 degrees relativeto the substantially vertical fold lines 18 in the blanks 11, 12. Theangle A may vary depending upon the size and shape of the notches 40.

As described in greater detail, the first and second bottom closurepanels 25, 26 of the first blank 11 include one or more notched edges 24that correspondingly engage one another to form the container bottom.Similarly, the first and second bottom closure panels 30, 31 of thesecond blank 12 include one or more notched edges 24 thatcorrespondingly engage one another to form a container bottom 29.

The notched edges 24 strengthen the container bottom and counter thereduced surface area of the bottom panels 25, 26, 30, 31 resulting fromthe efficient nesting of the blanks 11, 12 on the unitary sheet 10. Incomparing known containers depicted in FIGS. 2-3B to the presentinvention depicted in FIGS. 6-8B, the reduction in available surfacearea of the bottom panels 25, 26 is evident. The overlapping sheetmaterial of the inventive bottom panels 25, 26 indicated by hiddendouble cross-hatched lines in FIGS. 6 and 7 is less than the overlappingmaterial of known bottom panels 25′, 26′ indicated by hidden doublecross-hatched lines in FIG. 2. In further detail, the area of overlap ofthe inventive bottom panels 25, 26 indicated by double cross-hatchedlines in FIGS. 8A and 8B is less than the area of overlap of knownbottom panels 25′, 26′ indicated by double cross-hatched lines in FIGS.3A and 3B.

The reduction in the overlapping sheet material in a container bottomand the area of overlap in the bottom panels 25, 26, 30, 31 results fromthe efficient nesting of the pair of blanks 11, 12 in the presentinvention. Specifically, the inventive sheet 10 illustrated in FIG. 4includes less sheet scrap S (represented by parallel doublecross-hatched lines) than the known sheet illustrated in FIG. 1.Accordingly, the present invention increases manufacturing efficienciesby reducing sheet scrap S in a sheet, yet addresses the potentiallyweakened bottom by providing bottom panels having engagement notchesthat secure the bottom panels to one another and strengthen thecontainer bottom 29.

In terms of relative percent, the sheet scrap S illustrated in theinventive sheet of FIG. 4 is approximately 27% of the sheet scrap S′illustrated in the known sheet of FIG. 1. Further, the overlapping sheetmaterial illustrated in the inventive container bottom 29 of FIG. 6 isapproximately 26% of the overlapping sheet material illustrated in theknown container bottom 29′ of FIG. 2.

Directing attention to the first blank 11 of FIG. 4, one embodiment ofthe present invention may also provide first and second locking closureflaps 41, 42 connected to edges of the first and second side panels 15,16, respectively. The first and second locking closure flaps 41, 42 ofthe first blank 11 are positioned on the unitary sheet 11 opposite thenon-linear separation interface 13 and secures the top of the container60 formed from the blank 11. This particular embodiment also providesfirst and second top closure panels 47, 48 connected to edges of thefront and rear panels 14, 17 of the first blank 11. The top closurepanels 47, 48 form a part of the top of the container 60 and arepositioned on the sheet 11 opposite the non-linear separation interface13. The first blank 11 may also include first and second tuck flaps 52,53 connected to edges of the first and second top closure panels 47, 48,respectively, opposite the front and rear panels 14, 17. The tuck flaps52, 53 secure the top closure panels 47, 48 to each other. A glue flap56 is provided in the first blank 11 to assist in construction of thecontainer 60 formed from the blank 11. The glue flap 56 is connected toan edge of the rear panel 17 of the first blank 11, opposite the secondside panel 16, and is eventually secured to the first side panel 15 uponconstruction of the container 60.

Referring now to the second blank 12 of FIG. 4, the invention providesfirst and second locking closure flaps 45, 46 connected to edges of thefirst and second side panels 21, 22 of the second blank 12,respectively. The first and second locking closure flaps 45, 46 of thesecond blank 12 are positioned on the unitary sheet 11 opposite thenon-linear separation interface 13 and secures the top of the container60 formed from the blank. The second blank 12 may further include firstand second top closure panels 50, 51 connected to edges of the front andrear panels 20, 23, respectively. The first and second top closurepanels 50, 51 are positioned on the sheet 10 opposite the non-linearseparation interface 13 and form a part of the top of the container.First and second tuck flaps 54, 55 are provided on the second blank 12and are connected to edges of the first and second top closure panels50, 51, respectively, opposite the front and rear panels 20, 23. Toassist in construction of the identical container, the second blank 12may include a glue flap 57 connected to an edge of the rear panel 23 ofthe second blank, opposite the second side panel 22.

As depicted in FIG. 4, the first and second blanks 11, 12 are orientedon the sheet asymmetrically about a vertical axis of symmetry. Stateddifferently, the body panels 14, 15, 16, 17, 20, 21, 22, 23 of the firstand second blanks 11, 12 are oriented on the sheet in a non-lineararrangement. In a novel aspect of the invention, the non-lineararrangement in connection with the separation interface 13 reduces sheetscrap S and promotes manufacturing efficiencies.

The invention also provides a container 60 formed from the first orsecond blank 11, 12 as described above. As shown in FIGS. 6-8B, thecontainer 60 includes an interlocking container bottom 29 that isautomatically formed upon construction. The container 60 includes firstand second bottom closure panels 25, 26 that are secured to one another,first and second bottom closure flaps 27, 28 secured to the first andsecond bottom closure flaps, a substantially rectangular front panel 14connected to the first bottom closure panel 25, and a substantiallyrectangular rear panel 17 connected to the second bottom closure panel26. The container 60 further includes a substantially rectangular firstside panel 15 connected to the first bottom closure flap 27 and torespective edges of the front and rear panels 14, 17, and asubstantially rectangular second side panel 16 secured to the secondbottom closure flap 28 and to respective edges of the front and rearpanels 14, 17. As constructed, the front and rear panels 14, 17 and thefirst and second side panels 15, 16 define substantially parallelplanes, respectively.

In another novel aspect of the invention, the first and second bottomclosure panels 25, 26 include notched edges 24 that correspondinglyengage one another to form the container bottom 29. Upon construction,portions of the first and second bottom closure flaps 27, 28 arepositioned between overlapping portions of the first and second bottomclosure panels 25, 26.

Construction of the container bottom 29 is illustrated in FIGS. 9A-9C.In further detail, the glue flap 56 is adhered to the first side panel15 to form the basic container structure. Thereafter, a portion of thefirst bottom closure flap 27 is secured to the first bottom glue flap 35of the first bottom closure panel 25. Further, a portion of the secondbottom closure flap 28 is secured to the second bottom glue flap 36 ofthe second bottom closure panel 26. At this stage, the partially formedcontainer may be folded substantially flat such that the cut-score lines39 defining the first and second bottom glue flaps 35, 36 permit thefolding of the first side panel 15 and rear panel 17 against the secondside panel 16 and front panel 14, respectively. In this substantiallyflat configuration, the first bottom closure panel 25 is substantiallyadjacent to the front panel 14, the second bottom closure panel 26 issubstantially adjacent to the rear panel 17, the first bottom closureflap 27 is substantially adjacent to the first side panel 15, and thesecond bottom closure flap 28 is substantially adjacent to the secondside panel 16.

Further, portions of the first and second bottom closure panels 25, 26are substantially adjacent to one another, and are substantiallyadjacent to the first and second bottom closure flaps 27, 28,respectively. Subsequently, the container 60 may be expanded by pullingthe first side panel 15 and rear panel 17 away from the front panel 14and second side panel 16. In forming the container bottom 29, a user maymanipulate the panels to advance the notched edges 24 of the first andsecond bottom closure panels 25, 26 towards one another until theengagement notches 40 correspondingly engage one another to thereby formthe container bottom 29.

In the drawings and specification, there have been disclosed typicalembodiments on the invention and, although specific terms have beenemployed, they have been used in a generic and descriptive sense onlyand not for purposes of limitation, the scope of the invention being setforth in the following claims.

1. A nested pair of blanks on a unitary sheet, comprising: a first blankfor forming a container, said first blank having one or more body panelsconnected to one another and oriented horizontally, said first blankhaving one or more bottom panels connected to edges of said one or morebody panels of said first blank; a second blank for forming an identicalcontainer, said second blank having one or more body panels connected toone another and oriented horizontally, said second blank having one ormore bottom panels connected to edges of said one or more body panels ofsaid second blank; and a non-linear separation interface connecting saidfirst and second blanks to one another in a rotationally invertedrelationship that reduces sheet scrap; wherein said one or more bottompanels of said first and second blanks define said non-linear separationinterface.
 2. A nested pair of blanks according to claim 1, wherein saidsheet comprises paperboard.
 3. A nested pair of blanks according toclaim 1, wherein: said first blank having one or more notched edges thatcorrespondingly engage one another to form a container bottom uponseparation of said blank from said sheet and construction of thecontainer; and said second blank having one or more notched edges thatcorrespondingly engage one another to form a container bottom uponseparation of said blank from said sheet and construction of theidentical container.
 4. A nested pair of blanks according to claim 1,wherein: edges of said one or more bottom panels of said first blankhaving engagement notches that correspondingly engage one another toform the container bottom upon separation of said blank from said sheetand construction of the container; and edges of said one or more bottompanels of said second blank having engagement notches thatcorrespondingly engage one another to form the container bottom uponseparation of said blank from said sheet and construction of theidentical container.
 5. A nested pair of blanks according to claim 1,wherein at least one of said one or more bottom panels of said firstblank is connected to and nested vertically with at least one of saidone or more bottom panels of said second blank.
 6. A nested pair ofblanks according to claim 1, wherein said non-linear separationinterface is further defined by: one or more bottom flaps connected toedges of said one or more body panels of said first blank; and at leastone of said one or more bottom flaps of said first blank is connected toand nested vertically with at least one of said one or more bottompanels of said second blank.
 7. A nested pair of blanks according toclaim 1, wherein said non-linear separation interface is further definedby: one or more bottom flaps connected to edges of said one or more bodypanels of said second blank; and at least one of said one or more bottomflaps of said second blank is connected to and nested vertically with atleast one of said one or more bottom panels of said first blank.
 8. Anested pair of blanks according to claim 1, wherein said non-linearseparation interface is further defined by: one or more bottom flapsconnected to edges of said one or more body panels of said first blank;and one or more bottom flaps connected to edges of said one or more bodypanels of said second blank; at least one of said bottom panels of saidfirst blank is connected to and vertically nested with at least one ofsaid one or more bottom panels of said second blank and at least one ofsaid bottom flaps of said second blank.
 9. A nested pair of blanksaccording to claim 8, wherein at least one of said bottom panels of saidsecond blank is connected to and vertically nested with at least one ofsaid one or more bottom panels of said first blank and at least one ofsaid one or more bottom flaps of said first blank.
 10. A nested pair ofblanks according to claim 1, wherein each said first and second blanksis asymmetrical about a vertical axis of symmetry.
 11. A nested pair ofblanks according to claim 1, wherein said body panels of said first andsecond blanks are oriented on said sheet in a non-linear arrangement.12. A nested pair of blanks according to claim 1, wherein said one ormore body panels of said first blank include: a substantiallyrectangular front panel, said front panel having opposing first andsecond side panels; and a substantially rectangular rear panel connectedto said front panel by said second side panel.
 13. A nested pair ofblanks according to claim 12, wherein said one or more bottom panels ofsaid first blank include: at least one bottom panel connected to an edgeof said front panel; and at least one bottom panel connected to an edgeof said rear panel.
 14. A nested pair of blanks according to claim 1,wherein said one or more body panels of said second blank include: asubstantially rectangular front panel, said front panel having opposingfirst and second side panels; and a substantially rectangular rear panelconnected to said front panel by said second side panel.
 15. A nestedpair of blanks according to claim 14, wherein said one or more bottompanels of said second blank include: at least one bottom panel connectedto an edge of said front panel; and at least one bottom panel connectedto an edge of said rear panel.
 16. A nested pair of blanks according toclaim 1, wherein: said first blank having one or more bottom flapsconnected to edges of said one or more body panels of said first blank;and said second blank having one or more bottom flaps connected to edgesof said one or more body panels of said second blank.
 17. A nested pairof blanks on a unitary sheet, comprising: a first blank for forming acontainer, said first blank having a substantially rectangular frontpanel, said front panel having opposing first and second side panels, asubstantially rectangular rear panel connected to said front panel bysaid second side panel, and a bottom panel connected to an edge of saidfront panel; a second blank for forming an identical container, saidsecond blank having: a substantially rectangular front panel, said frontpanel having opposing first and second side panels, a substantiallyrectangular rear panel connected to said front panel by said second sidepanel; and a bottom panel connected to an edge of said rear panel; and anon-linear separation interface connecting said first and second blanksto one another in a rotationally inverted relationship that reducessheet scrap; wherein said one or more bottom panels of said first andsecond blanks define said non-linear separation interface.
 18. A nestedpair of blanks according to claim 17, wherein said sheet comprisespaperboard.
 19. A nested pair of blanks according to claim 17, wherein:said first blank having one or more notched edges that correspondinglyengage one another to form a container bottom upon separation of saidblank from said sheet and construction of the container; and said secondblank having one or more notched edges that correspondingly engage oneanother to form a container bottom upon separation of said blank fromsaid sheet and construction of the identical container.
 20. A nestedpair of blanks according to claim 17, wherein said bottom panel of saidfirst blank is connected to and nested vertically with said bottom panelof said second blank.
 21. A nested pair of blanks according to claim 17,said non-linear separation interface is further defined by: a bottomflap connected to an edge of said first side panel of said first blank;and said bottom flap of said first blank is connected to and verticallynested with said bottom panel of said second blank.
 22. A nested pair ofblanks according to claim 17, said non-linear separation interface isfurther defined by: a bottom flap connected to an edge of said secondside panel of said second blank; and said bottom flap of said secondblank is connected to and vertically nested with said bottom panel ofsaid first blank.
 23. A nested pair of blanks according to claim 17,said non-linear separation interface is further defined by: a bottompanel connected to an edge of said rear panel of first blank; and abottom panel connected to an edge of said front panel of said secondblank; wherein said bottom panel connected to said rear panel of saidfirst blank is connected to and nested vertically with said bottom panelconnected to said front panel of said second blank.
 24. A nested pair ofblanks according to claim 23, wherein: edges of said bottom panels ofsaid first blank having engagement notches that correspondingly engageone another to form a container bottom upon separation of said blankfrom said sheet and construction of the container; and edges of saidbottom panels of said second blank having engagement notches thatcorrespondingly engage one another to form a container bottom uponseparation of said blank from said sheet and construction of theidentical container.
 25. A nested pair of blanks according to claim 23,said non-linear separation interface is further defined by: a bottomflap connected to an edge of said second side panel of said first blank;and said bottom flap connected to said second side panel of said firstblank is connected to and vertically nested with said bottom panelconnected to said front panel of said second blank.
 26. A nested pair ofblanks according to claim 23, said non-linear separation interface isfurther defined by: a bottom flap connected to an edge of said firstside panel of said second blank; and said bottom flap connected to saidfirst side panel of said second blank is connected to and verticallynested with said bottom panel connected to said rear panel of said firstblank.
 27. A nested pair of blanks according to claim 17, furthercomprising first and second locking closure flaps connected to edges ofsaid first and second side panels of said first blank, respectively,opposite said non-linear separation interface.
 28. A nested pair ofblanks according to claim 17, further comprising first and second topclosure panels connected to edges of said front and rear panels of saidfirst blank, respectively, opposite said non-linear separationinterface.
 29. A nested pair of blanks according to claim 28, furthercomprising first and second tuck flaps connected to edges of said firstand second top closure panels of said first blank, respectively,opposite said front and rear panels of said first blank.
 30. A nestedpair of blanks according to claim 17, further comprising a glue flapconnected to an edge of said rear panel of said first blank, oppositesaid second side panel of said first blank.
 31. A nested pair of blanksaccording to claim 17, further comprising first and second lockingclosure flaps connected to edges of said first and second side panels ofsaid second blank, respectively, opposite said non-linear separationinterface.
 32. A nested pair of blanks according to claim 17, furthercomprising first and second top closure panels connected to edges ofsaid front and rear panels of said second blank, respectively, oppositesaid non-linear separation interface.
 33. A nested pair of blanksaccording to claim 32, further comprising first and second tuck flapsconnected to edges of said first and second top closure panels of saidsecond blank, respectively, opposite said front and rear panels of saidsecond blank.
 34. A nested pair of blanks according to claim 17, furthercomprising a glue flap connected to an edge of said rear panel of saidsecond blank, opposite said second side panel of said second blank. 35.A nested pair of blanks on a unitary sheet, comprising: a first blankfor forming a container, said first blank having a substantiallyrectangular front panel, said front panel having opposing first andsecond side panels, a substantially rectangular rear panel connected tosaid front panel by said second side panel, a first bottom closure panelconnected to an edge of said front panel, a second bottom closure panelconnected to an edge of said rear panel, a first bottom closure flapconnected to an edge of said first side panel, and a second bottomclosure flap connected to an edge of said second side panel; and asecond blank for forming an identical container, said second blankhaving: a substantially rectangular front panel, said front panel havingopposing first and second side panels, a substantially rectangular rearpanel connected to said front panel by said second side panel, a firstbottom closure panel connected to an edge of said front panel, a secondbottom closure panel connected to an edge of said rear panel, a firstbottom closure flap connected to an edge of said first side panel, and asecond bottom closure flap connected to an edge of said second sidepanel; and a non-linear separation interface connecting said first andsecond blanks to one another in a rotationally inverted relationshipthat reduces sheet scrap.
 36. A nested pair of blanks according to claim35, wherein said one or more bottom closure panels and said one or morebottom closure flaps of said first and second blanks define saidnon-linear separation interface.
 37. A nested pair of blanks accordingto claim 35, wherein one or more of said bottom closure panels of saidfirst blank is connected to and nested vertically with one or more ofsaid bottom closure flaps of said second blank.
 38. A nested pair ofblanks according to claim 35, wherein one or more of said bottom closurepanels of said second blank is connected to and nested vertically withone or more of said bottom closure flaps of said first blank.
 39. Anested pair of blanks according to claim 35, wherein said first bottomclosure panel of said first blank is connected to and vertically nestedwith said second bottom closure panel and second bottom closure flap ofsaid second blank.
 40. A nested pair of blanks according to claim 35,wherein said second bottom closure panel of said first blank isconnected to and vertically nested with said first bottom closure paneland said first bottom closure flap of said second blank.
 41. A nestedpair of blanks according to claim 35, wherein said first bottom closureflap of said first blank is connected to and vertically nested with saidsecond bottom closure panel of said second blank.
 42. A nested pair ofblanks according to claim 35, wherein said second bottom closure flap ofsaid first blank is connected to and vertically nested with said firstbottom closure panel of said second blank.
 43. A nested pair of blanksaccording to claim 35, wherein said first bottom closure flap of saidsecond blank is connected to and vertically nested with said secondbottom closure panel of said first blank.
 44. A nested pair of blanksaccording to claim 35, wherein said second bottom closure flap of saidsecond blank is connected to and vertically nested with said firstbottom closure panel of said first blank.
 45. A nested pair of blanksaccording to claim 35, wherein: said first and second bottom closurepanels of said first blank having one or more notched edges thatcorrespondingly engage one another to form a container bottom uponseparation of said blank from said sheet and construction of thecontainer; and said first and second bottom closure panels of saidsecond blank having one or more notched edges that correspondinglyengage one another to form a container bottom upon separation of saidblank from said sheet and construction of the identical container.
 46. Acontainer having an interlocking container bottom, comprising: first andsecond bottom closure panels secured to one another, said first andsecond bottom closure panels having notched edges that correspondinglyengage one another to form a container bottom; first and second bottomclosure flaps secured to said first and second bottom closure flaps,portions of said first and second bottom closure flaps positionedbetween overlapping portions of said first and second bottom closurepanels; a substantially rectangular front panel connected to said firstbottom closure panel; a substantially rectangular rear panel connectedto said second bottom closure panel, said front panel and said rearpanel defining substantially parallel planes; a substantiallyrectangular first side panel connected to said first bottom closure flapand to respective edges of said front and rear panels; and asubstantially rectangular second side panel secured to said secondbottom closure flap and to respective edges of said front and rearpanels, said first side panel and said second side panel definingsubstantially parallel planes.